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Easy one for you guys

Discussion in 'XJ Technical Chat' started by PaulT, Jun 30, 2008.

  1. PaulT

    PaulT Member

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    First off, let me say 'THANK YOU" to everyone on the site. I've learned so much in the short time I've been here.


    Now...
    Noticed previously that my bike wouldn't start in gear with the clutch pulled in.
    Tonight when I got home from work, I got home, shut it down and was taking a look at a few things. In doing so, I hit the starter (bike in gear) and it jumped forward....hmmm
    so..clutch in, no start, in gear with no clutch, wants to.

    Simple as a connection that was put on wrong/backwards?
     
  2. RickCoMatic

    RickCoMatic Well-Known Member

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    A-symptomatic of the wrong type of Relay plugged-into the Harness where a Bona Fide "Safety Relay" should be.

    Having a generic or Lighting Relay in place of a SAFETY Relay is actually a dangerous situation.
    As you know ... the Starter Motor will engage with the BIKE IN GEAR>
    Furthermore ... the Bike will actually START; too, which is the extreme danger.

    You'll have to get a Safety Relay to replace the One that's in there now.
    The Safety Relay on your bike is:

    Under the tank
    Under the center frame member.
    To the rear of the Turn Signal Self Canceling Module
    Close to where the Tank is bolted to the frame at the front of the seat.

    If you unplug the Relay to test that it is the problem ...

    The Bike should NOT Start UNLESS the Bike IS actually in Neutral with the Neutral Light ON>
     
  3. PaulT

    PaulT Member

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    I knew you'd have the answer Rick
     
  4. RickCoMatic

    RickCoMatic Well-Known Member

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    If I knew how to do it ... I'd have a few pre-prepared answers for some of the questions that are surfacing these days.

    It's beginning to be like a movie I have seen a few times.

    Honestly, I think some of this stuff has been covered a few time in '07 and early '08.
     
  5. wizard

    wizard Active Member

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    The Bike should NOT Start UNLESS the Bike IS actually in Neutral with the Neutral Light ON> (quote RicoCoMatic)

    It says in the manual in Dos & Donts:
    Dont: start the engine without first ascertaining that the transmission is in neutral.
    Assuming this a new bike, they are talking about, how could it start?
     
  6. RickCoMatic

    RickCoMatic Well-Known Member

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    The Safety Relay and the Safety Circuit work in conjunction with the Starter Circuit.

    If the Side Stand is Down, the Relay Kills the Ignition if you shift out of Neutral.

    But, with the Bike IN Gear ... Sidestand UP ... The Clutch Switch shows the Relay that the Clutch Lever is Pulled allowing the Bike to Start when the Bike IS NOT in Neutral.

    If the wrong Relay is installed ... the Circuit is fooled and the Starter IS Engaged WITH the Bike IN Gear and the Clutch Lever NOT PULLED.

    Worse.
    When the Clutch Lever IS Pulled ... the Bike IN Gear ... The Start Button Pressed ... the Starter Motor IS NOT activated ... BUT, Immediately spins WITH the Bike IN Gear when the Cluthc Lever is RELEASED!

    Be sure to get the right Part Number for a Safety Relay.

    The Safety Relay is wired opposite (unlike) a generic or Lighting Relay.
     
  7. PaulT

    PaulT Member

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    Come to think of it, the kickstand was down when I first accidently hit the starter button.
     
  8. RickCoMatic

    RickCoMatic Well-Known Member

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    The main problem is ... the Safety Relay LOOKS EXACTLY like any other Relay.
    The Plug-in matches-up and the size is just the same. It's wired differently.

    (+)----(+)

    (-)-----(-) Generic wiring sample for illustration only.


    (+)----(-)

    (+)----(-) Safety Relay - example only.

    I'm not sure what the actual wiring is. But as you can see there is a huge difference.
     
  9. PaulT

    PaulT Member

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    I'm thinking the PO must have inadvertantly swapped the clutch and kickstand lines somewhere.

    Kickstand down, switch closed..bike thinks clutch is in
    Clutch off, switch open....bike thinks kickstand is up.

    Time to grab my trusty meter and trace out the lines
     

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